My ZZR400k1 to ZZR600d3 conversion

[ducatilover]

The 400 made me angry, it was crap. Did run right, bits kept falling apart etc and I eventually decided I'll stop being a tight prick and hunt down a 600 motor.

I lucked across one last week and jumped on it, it was a near complete bike, minus front fairings, rear shock and carbs. I found carbs too. I went down to Wellington to drop the CB400 SF off last Saturday, so I picked the spare bike/pile and carbs up.
Ordered new clutch cable and carb rubbers and finally finished the job today, all in all a pretty easy conversion to do, I've done far worse.

I struggled lifting the 600 engine on to the jack, but, my trusty flatmate arrived home and casually lifted it off the ground :blink: So after I stopped feeling insignificant I threw the mounting bolts in and that was the worst part over, the rest is a stroll in the park, the 600 dash goes straight in (260k speedo which looks cooler) and all the wiring is the same, even the CDI is the same.

I have just to make some mounts for the cans, which happen to be Neptunes and sound quite yummy.

It started first pop, no smoke apart from where I spilled coolant on the headers :facepalm:

Pics to come later

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[ducatilover]

Righto no photos yet sorry, maybe tomorrow :innocent:

I'm having problems with wide open throttle over 5000rpm in top and 7-9000rpm in first depending on how you roll the throttle.
It's flooding the bastard.
It stutters around and then dies under load, cannot get over 120 in 6th.
Pulls very well down low and fairly clean up to 5000rpm in 5th then begins to flatten.

Have: Got carbs cleaned, plug change, leads, coils all changed.
It has a foam element filter, which I just oiled.
Has twin Neptune cans, so if anything it should make it leaner.
My theory here, as the slides move freely and rise with throttle when engine's running, everything is happy and clean in the carbs, the airbox may be leaking, causing a lack in air velocity. If the slides can be opening with relatively small amounts of vacuum, this would explain the fouling up issue, too much gas and cannot draw enough air.

Something like that, does that mumbo jumbo make sense?

[zeocen]

I have no technical knowledge for you, I just wanted to congrats you on doing the conversion on these awesome bikes!

I've had a ZZR250, 600, 1100, 1200 and ZX14 so I guess you could say I like these bikes!
I had a 1992 ZZR600 in red, such a great bike. Once you get yours sorted I think you will love the extra power it gives, if I remember rightly it was one of the first 600 bikes to get close to 100HP.

Wish I knew how to do all that stuff, seems like an awesome thing to do on rainy days.

[ducatilover]

I have no technical knowledge for you, I just wanted to congrats you on doing the conversion on these awesome bikes!

I've had a ZZR250, 600, 1100, 1200 and ZX14 so I guess you could say I like these bikes!
I had a 1992 ZZR600 in red, such a great bike. Once you get yours sorted I think you will love the extra power it gives, if I remember rightly it was one of the first 600 bikes to get close to 100HP.

Wish I knew how to do all that stuff, seems like an awesome thing to do on rainy days.
I've always been a fan of the 600 and 1100, I'm young and they were the business in my youth.
It currently goes very well down low, minute stumble from slightly high fuel levels, but when it seems to get on the main circuit it kills itself. :facepalm:

They are a cool machine and I'm looking forward to getting her sorted out

[vifferman]

Good stuff, Sir!
I hope you get the fuelling sorted soonly and without too much trouble.

[hayd3n]

have you fitted the 600 cdi?

[ducatilover]

Good stuff, Sir!
I hope you get the fuelling sorted soonly and without too much trouble.
Thanks :yes:

have you fitted the 600 cdi?
According to the ZZR gurus on ZZR-international.co.uk they are the same CDI unit.
Correct my if I am wrong....:yes:


It runs better without the airbox, but will not climb over 10-11k (I didn't try that in first or second though, will go do it now) It hauls arse in the 6000-10k range, pulls great from idle to between 3 and 4k the seems to be fluffy in between there.

It just feels like it is still over fuelling in the top end :facepalm:
Have ordered some 135 and 138 main jets to see if that cures it.

[tigertim20]

bummer, good luck with your project!!

[ducatilover]

Went to the garage to have a tinker yesterday morning and found a nice flat battery awaiting me :facepalm: Charged battery and started hunting the problem down. Bogan gave me some handy tips and I found some fucked windings in the alternator :shutup:

Whipped the cover off the 400 motor and stole that one, all is happy and charging nicely now.
Sadly it didn't fix my massive jetting problem :innocent:

Gave it a poor excuse for a wash and took some pictures with the stupid cellphone, damn camera and batteries have gone for a walk :bye:

Who likes rim stripes? I love them :love:240346240347240348240349240350240351

[ducatilover]

Bike's sorted and runs beautifully now, goes like a raped cat (I tested it, raped cats are bloody quick) :yes: Very smooth and comfy to ride, but I'm not a fan of the brakes. Easy fix, CBR/VTR Nissin calipers :rockon:

The problems were:

Jetting was miles off, now has 135s in it.
The 400 CDI needs a signal/complete circuit in the speed limiter circuit. There's a unit that sends signal to the cdi when the little metal wheel in the speedo housing passes through two magnets, when this circuit is disconnected, it sets the limiter to 10,000rpm as that's 180k with the 400 gearing.
So, pull that out the 400 speedo. Use the 400 wiring harness for the clocks.
Plug the unit in, leave it hanging around (I cable tied it to the little frame the speedo sits on) and viola, proper 15,000rpm limiter (I haven't tried that, it's wet and I am a pussy) and no speed restrictor. A professional rider reported from his race track that it pulls very nicely through the revs.

[White trash]

ZZR600 was the first bike I rode that truly scared me at the speed it was capable of. Still a fucking quick 600cc machine and sooooo plush and comfortable. My mental cousin races one in fact.

[ducatilover]

ZZR600 was the first bike I rode that truly scared me at the speed it was capable of. Still a fucking quick 600cc machine and sooooo plush and comfortable. My mental cousin races one in fact.

It's certainly fast enough for now :scooter: It gets up and goes up the top (According to said professional rider) and it's just so bloody nice to ride. I don't see myself getting knee, wrist, hand, hip and back pains like the CB gave me.

Sounds horn too with those Neptunes :love:

Gave me a hella surprise in a thrid gear roll on :rockon:

[bogan]

In typical kwaka fashion parts are failing as quick as they get fixed :Pokey:

Here's a pic of the stator, was getting 1ohm from the stator wires to ground, and I reckon still supplying some current but not enough.

Thoughts? How hard is it to rewind?

[ducatilover]

Thanks bro, got to get a camera that works..

I'll rip it apart, it may be shorting to the engine so will check it very carefully and see what's what.
Dad reckons they aren't hard to re-wind, just get the correct gauge wire and count the amount of windings per pole.

Probably not today, cannot really walk/bend, fucked my back last night :weep:

[ducatilover]

Quick wee update on the ZZR6.
Jetting done.
It isn't running out of electricity.
It has no centre stand to dig the road up with.
Every 0-ring in the cooling system has been replaced.
500km in the last two days :yes::scooter:

Has Pilot Powers, they are great.